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Carbon fiber sizing agent, carbon fiber strand, and fiber-reinforced composite

a technology of carbon fiber strands and sizing agents, which is applied in the direction of fiber treatment, textiles and papermaking, transportation and packaging, etc., can solve the problems of deteriorating the properties of resultant fiber-reinforced composites, insufficient cohesion of reinforcement fiber strands, and inability to feed continuously chopped fiber to pellet manufacturing, etc., to achieve good bonding performance, excellent performance, and excellent properties

Inactive Publication Date: 2018-04-03
MATSUMOTO YUSHI SEIYAKU
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a carbon fiber sizing agent that can effectively bond with thermoplastic matrix resin, resulting in a high-quality carbon fiber strand that can be used to reinforce composite materials. The carbon fiber strand exhibits outstanding properties when combined with thermoplastic resin, making it ideal for use in various applications.

Problems solved by technology

The chopped fiber should have sufficient cohesion when it is knead with a thermoplastic resin to be manufactured into pellets, and chopped fiber having insufficient cohesion cannot be fed constantly to pellet manufacturing.
In addition, reinforcement fiber strands having insufficient fiber cohesion sometimes break to deteriorate the properties of resultant fiber-reinforced composites.
However, thermoplastic matrix resins including inherently nonpolar polyolefin resins are more viscous than thermosetting resins in molten form, and sometimes fail to sufficiently impregnate fiber strands applied with sizing agents disclosed in prior arts due to insufficient wettability on the fiber strands.
Thus the resultant composites sometimes have mechanical properties insufficient for meeting demands for composites.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

examples

[0091]The present invention is specifically explained with the following examples, though the present invention is not restricted within the scope of the examples. The percent mentioned in the following examples means “wt % (weight percent)” unless otherwise specified. The properties were measured in the methods described below.

[Glass Transition Temperature]

[0092]The glass transition temperature of about 10 mg of a sample was determined with a differential scanning calorimeter (DSC, the Jade DSC Lab system, manufactured by PerkinElmer Instruments) according to JIS K 7121 with elevating temperature at the rate of 10 deg.C. / min. Specifically, a sample was accurately weighed to 10±1 mg and set in the differential scanning calorimeter, and the sample was heated under the elevating temperature up to the temperature 30 deg.C. higher than the melting temperature of the sample previously determined. Then the temperature of the sample was lowered to the temperature 50 deg.C. lower than the g...

example of production 1

[0102]In a reactor charged with nitrogen gas, 950 parts of dimethyl isophthalate, 1000 parts of diethylene glycol, 0.5 parts of zinc acetate and 0.5 parts of antimony trioxide were placed, and transesterification was conducted at a temperature ranging from 140 deg.C. to 220 deg.C. for 3 hours. Then 30 parts of sodium 5-sulfoisophthalate was added and esterification was conducted at a temperature ranging from 220 deg.C. to 260 deg.C. for 1 hour followed with condensation reaction under reduced pressure at a temperature ranging from 240 deg.C. to 270 deg.C. for 2 hours. The components of the resultant aromatic polyester resin determined in an analysis with NMR are as follows.

[0103]Isophthalic acid: 49 mol %

[0104]Diethylene glycol: 50 mol %

[0105]Sodium 5-sulfoisophthalate: 1 mol %

[0106]Then 200 parts of the resultant aromatic polyester resin and 100 parts of ethylene glycol monobutyl ether are placed in an emulsification device and agitated at a temperature ranging from 150 deg.C. to 1...

example of production 2

[0107]In a reactor charged with nitrogen gas, 760 parts of dimethyl terephthalate, 190 parts of dimethyl isophthalate, 750 parts of ethylene glycol, 250 parts of diethylene glycol, 0.5 parts of zinc acetate and 0.5 parts of antimony trioxide were placed, and transesterification was conducted at a temperature ranging from 140 deg.C. to 220 deg.C. for 3 hours. Then 30 parts of sodium 5-sulfoisophthalate was added and esterification was conducted at a temperature ranging from 220 deg.C. to 260 deg.C. for 1 hour followed with condensation reaction under reduced pressure at a temperature ranging from 240 deg.C. to 270 deg.C. for 2 hours. The components of the resultant aromatic polyester resin determined in an analysis with NMR are as follows.

[0108]Terephthalic acid: 39 mol %

[0109]Isophthalic acid: 10 mol %

[0110]Ethylene glycol: 40 mol %

[0111]Diethylene glycol: 10 mol %

[0112]Sodium 5-sulfoisophthalate: 1 mol %

[0113]Then 200 parts of the resultant aromatic polyester resin and 100 parts of...

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Abstract

A carbon fiber sizing agent imparts good bonding performance to carbon fiber, is used to reinforce a thermoplastic matrix resin, and provides a carbon fiber strand applied with the sizing agent and a fiber-reinforced composite reinforced with the carbon fiber strand. The sizing agent for carbon fiber is used to reinforce thermoplastic matrix resin. The sizing agent essentially contains a polymer component having a glass transition temperature of at least 20 deg.C. and exhibits no endothermic peaks indicating an endothermic heat of fusion due to crystalline melting of at least 3 J / g in a determination with a DSC. The weight ratio of the polymer component is 10 to 100 wt % of the nonvolatile components of the sizing agent. The polymer component is at least one component selected from the group consisting of an aromatic polyester resin, aromatic polyester-polyurethane resin and amine-modified aromatic epoxy resin.

Description

TECHNICAL FIELD[0001]The present invention relates to a sizing agent for carbon fiber employed in reinforcement of thermoplastic matrix resin, and a carbon fiber strand and fiber-reinforced composite manufactured therewith. More precisely, the present invention relates to a carbon fiber sizing agent which imparts good bonding performance to a carbon fiber strand with a thermoplastic matrix resin, and a carbon fiber strand and fiber-reinforced composite manufactured therewith.TECHNICAL BACKGROUND[0002]Fiber-reinforced composites manufactured by reinforcing plastic materials (called matrix resins) with various synthetic fibers are used widely in automotive application, aviation and space application, sporting and leisure goods application, and general industrial use. Fibers employed for the composites include inorganic fibers, such as carbon fiber, glass fiber and ceramic fiber; and organic fibers, such as aramid fiber, polyamide fiber and polyethylene fiber. These synthetic fibers ar...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): D06M15/63D06M15/507D06M15/263C08J5/24D06M15/568D06M15/55D06M101/40
CPCD06M15/63C08J5/24D06M15/263D06M15/507D06M15/568D06M15/55Y10T428/2918C08J2300/22D06M2101/40C08J5/06
Inventor HASHIMOTO, YOSHIOSHIMIZU, YUSUKENAKAGAWA, MIKIO
Owner MATSUMOTO YUSHI SEIYAKU